Robotic Devices with On Board Control &amp; Related Systems &amp; Devices

ABSTRACT

The embodiments disclosed herein relate to various medical device components, including components that can be incorporated into robotic and/or in vivo medical devices. Certain embodiments include various modular medical devices for in vivo medical procedures.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/573,849, entitled “ROBOTIC SURGICAL DEVICES, SYSTEMS, AND RELATEDMETHODS,” filed on Oct. 9, 2012, which claims priority to U.S.Provisional Application 61/680,809, filed Aug. 8, 2012, which isincorporated herein in its entirety by this reference.

TECHNICAL FIELD

The embodiments disclosed herein relate to various medical devices andrelated components, including robotic and/or in vivo medical devices andrelated components. Certain embodiments include various robotic medicaldevices, including robotic devices that are disposed within a bodycavity and positioned using a support component disposed through anorifice or opening in the body cavity. Further embodiment relate tomethods of operating the above devices.

BACKGROUND

Invasive surgical procedures are essential for addressing variousmedical conditions. When possible, minimally invasive procedures such aslaparoscopy are preferred.

However, known minimally invasive technologies such as laparoscopy arelimited in scope and complexity due in part to 1) mobility restrictionsresulting from using rigid tools inserted through access ports, and 2)limited visual feedback. Known robotic systems such as the da Vinci®Surgical System (available from Intuitive Surgical, Inc., located inSunnyvale, Calif.) are also restricted by the access ports, as well ashaving the additional disadvantages of being very large, very expensive,unavailable in most hospitals, and having limited sensory and mobilitycapabilities.

There is a need in the art for improved surgical methods, systems, anddevices.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a diagram showing a robotic surgical system, including arobotic device positioned inside a body, according to one embodiment.

FIG. 1B is a perspective view of the device of FIG. 1A.

FIG. 2A is a perspective view of a robotic medical device, according toone embodiment.

FIG. 2B is a perspective view of a robotic medical device showing theaxes of rotation, according to one embodiment.

FIG. 3 is a perspective view of a robotic device and related equipment,according to one embodiment.

FIG. 4 is a perspective view of a robotic device and related equipment,according to one embodiment.

FIG. 5 is a perspective view of a robotic device and related equipment,according to one embodiment.

FIG. 6A is a perspective view of the arm of a robotic device poised tobe inserted into a patient's cavity, according to one embodiment.

FIG. 6B is a perspective view of the arm of FIG. 6A, rotated to show analternate angle.

FIG. 7 is a side view of a robotic device during insertion and assembly,according to one embodiment.

FIG. 8 is another perspective view of the robotic device with anovertube for assembly, according to one embodiment.

FIG. 9 is another perspective view of the robotic device duringassembly, according to one embodiment.

FIG. 10 is another perspective view of the robotic device and relatedequipment, according to one embodiment.

FIG. 11 is a view of a robotic device and related equipment, accordingto one embodiment.

FIG. 12A is a perspective view of a robotic medical device, according toone embodiment.

FIG. 12B is a cutaway perspective view of a robotic medical device,according to one embodiment.

FIG. 12C is a perspective view of a printed circuit board of a roboticmedical device, according to one embodiment.

FIG. 12D is a cutaway perspective view of a robotic medical device,according to one embodiment.

FIG. 13A is a side cutaway view of a robotic medical device, accordingto one embodiment.

FIG. 13A is a side cutaway view of a robotic medical device, accordingto one embodiment.

FIG. 13B is a front view of a forearm of a robotic medical device,according to one embodiment.

FIG. 13C is a rear perspective view of a forearm of a robotic medicaldevice, according to one embodiment.

FIG. 13D is cutaway perspective view of a forearm of a robotic medicaldevice, according to one embodiment.

FIG. 14 shows a cut away view of a robotic forearm, according to oneembodiment.

FIG. 15A shows a cutaway side view of a robotic upper arm, according toone embodiment.

FIG. 15B shows an end view of a robotic upper arm, according to oneembodiment.

FIG. 15C shows a perspective view of a robotic upper arm, according toone embodiment.

FIG. 15D shows a cutaway perspective view of a robotic upper arm,according to one embodiment.

FIG. 16A shows a cutaway side view of a robotic shoulder, according toone embodiment.

FIG. 16B shows an end view of a robotic shoulder, according to oneembodiment.

FIG. 16C shows a perspective view of a robotic shoulder, according toone embodiment.

FIG. 16D shows a perspective cutaway view of a robotic shoulder,according to one embodiment.

FIG. 17A shows a top cutaway view of robotic device cabling, accordingto one embodiment.

FIG. 17B shows a cutaway perspective view of robotic device circuitboards, according to one embodiment.

FIG. 18 shows a block diagram of electronics for a robotic device/arm,according to one embodiment.

FIG. 19 shows a block diagram of electronics for a robotic device/arm,according to one embodiment.

FIG. 20A shows a robotic arm according to one embodiment.

FIG. 20B shows a robotic arm sleeve mold, according to one embodiment.

FIG. 21A shows a robotic arm and sleeve making process overview,according to one embodiment.

FIG. 21B shows a robotic arm and sleeve making process overview,according to one embodiment.

FIG. 22B shows the rolled edges of the protective sleeve and the sleeveplaced on the robotic arm, according to one embodiment.

FIG. 22B shows the rolled edges of the protective sleeve and the sleeveplaced on the robotic arm, according to one embodiment.

DETAILED DESCRIPTION

The various systems and devices disclosed herein relate to devices foruse in medical procedures and systems. More specifically, variousembodiments relate to various medical devices, including robotic devicesand related methods and systems.

It is understood that the various embodiments of robotic devices andrelated methods and systems disclosed herein can be incorporated into orused with any other known medical devices, systems, and methods.

For example, the various embodiments disclosed herein may beincorporated into or used with any of the medical devices and systemsdisclosed in copending U.S. application Ser. No. 12/192,779 (filed onAug. 15, 2008 and entitled “Modular and Cooperative Medical Devices andRelated Systems and Methods”), U.S. Pat. No. 7,492,116 (filed on Oct.31, 2007 and entitled “Robot for Surgical Applications”), U.S. Pat. No.7,772,796 (filed on Apr. 3, 2007 and entitled “Robot for SurgicalApplications”), Ser. No. 11/947,097 (filed on Nov. 27, 2007 and entitled“Robotic Devices with Agent Delivery Components and Related Methods),Ser. No. 11/932,516 (filed on Oct. 31, 2007 and entitled “Robot forSurgical Applications”), Ser. No. 11/766,683 (filed on Jun. 21, 2007 andentitled “Magnetically Coupleable Robotic Devices and Related Methods”),Ser. No. 11/766,720 (filed on Jun. 21, 2007 and entitled “MagneticallyCoupleable Surgical Robotic Devices and Related Methods”), Ser. No.11/966,741 (filed on Dec. 28, 2007 and entitled “Methods, Systems, andDevices for Surgical Visualization and Device Manipulation”), Ser. No.12/171,413 (filed on Jul. 11, 2008 and entitled “Methods and Systems ofActuation in Robotic Devices”), 60/956,032 (filed on Aug. 15, 2007),60/983,445 (filed on Oct. 29, 2007), 60/990,062 (filed on Nov. 26,2007), 60/990,076 (filed on Nov. 26, 2007), 60/990,086 (filed on Nov.26, 2007), 60/990,106 (filed on Nov. 26, 2007), 60/990,470 (filed onNov. 27, 2007), 61/025,346 (filed on Feb. 1, 2008), 61/030,588 (filed onFeb. 22, 2008), 61/030,617 (filed on Feb. 22, 2008), U.S. Pat. No.8,179,073 (issued May 15, 2011, and entitled “Robotic Devices with AgentDelivery Components and Related Methods”), Ser. No. 12/324,364 (filedNov. 26, 2008, U.S. Published App. 2009/0171373 and entitled“Multifunctional Operational Component for Robotic Devices”), and Ser.No. 13/493,725 (filed Jun. 11, 2012 and entitled “Methods, Systems, andDevices Relating to Surgical End Effectors”), all of which are herebyincorporated herein by reference in their entireties.

Certain device and system implementations disclosed in the applicationslisted above can be positioned within a body cavity of a patient incombination with a support component similar to those disclosed herein.An “in vivo device” as used herein means any device that can bepositioned, operated, or controlled at least in part by a user whilebeing positioned within a body cavity of a patient, including any devicethat is coupled to a support component such as a rod or other suchcomponent that is disposed through an opening or orifice of the bodycavity, also including any device positioned substantially against oradjacent to a wall of a body cavity of a patient, further including anysuch device that is internally actuated (having no external source ofmotive force), and additionally including any device that may be usedlaparoscopically or endoscopically during a surgical procedure. As usedherein, the terms “robot,” and “robotic device” shall refer to anydevice that can perform a task either automatically or in response to acommand.

Certain embodiments provide for insertion of the present invention intothe cavity while maintaining sufficient insufflation of the cavity.Further embodiments minimize the physical contact of the surgeon orsurgical users with the present invention during the insertion process.Other implementations enhance the safety of the insertion process forthe patient and the present invention. For example, some embodimentsprovide visualization of the present invention as it is being insertedinto the patient's cavity to ensure that no damaging contact occursbetween the system/device and the patient. In addition, certainembodiments allow for minimization of the incision size/length. Furtherimplementations reduce the complexity of the access/insertion procedureand/or the steps required for the procedure. Other embodiments relate todevices that have minimal profiles, minimal size, or are generallyminimal in function and appearance to enhance ease of handling and use.

Certain implementations disclosed herein relate to “combination” or“modular” medical devices that can be assembled in a variety ofconfigurations. For purposes of this application, both “combinationdevice” and “modular device” shall mean any medical device havingmodular or interchangeable components that can be arranged in a varietyof different configurations. The modular components and combinationdevices disclosed herein also include segmented triangular orquadrangular-shaped combination devices. These devices, which are madeup of modular components (also referred to herein as “segments”) thatare connected to create the triangular or quadrangular configuration,can provide leverage and/or stability during use while also providingfor substantial payload space within the device that can be used forlarger components or more operational components. As with the variouscombination devices disclosed and discussed above, according to oneembodiment these triangular or quadrangular devices can be positionedinside the body cavity of a patient in the same fashion as those devicesdiscussed and disclosed above.

FIGS. 1A and 1B depict an exemplary system 1 that includes a roboticsurgical device 10 disposed within the inflated peritoneal cavity 2 of apatient. It is understood that the various device and system embodimentsdisclosed herein, including the system 1 of FIGS. 1A and 1B, can be usedfor a variety of surgical procedures and tasks including, but notlimited to, tissue biopsy, tissue dissection, or tissue retraction. Forexample, as shown in FIGS. 1A and 1B in accordance with one embodiment,the device 10 can be used to dissect tissue in the peritoneal cavity 2.In this system embodiment, a user (such as, for example, a surgeon) 3operates a user interface 4 to control the device 10. The interface 4 isoperably coupled to the device 10 by a cable 5 or other type of physicalconnection that provides for electronic power and/or electricalcommunication back and forth between the interface 4 and the device 10.Alternatively, the interface 4 can be operably coupled to the device 10wirelessly. It is understood that the device embodiments disclosedherein can also be used with any other known system, including any ofthe systems disclosed in the various patent applications incorporated byreference above and elsewhere herein.

FIG. 2A depicts a robotic medical device 10, in accordance with oneimplementation. According to one embodiment, the device is an in vivodevice. This device 10 embodiment as shown includes a body 12 that hastwo components 14A, 14B, which in this embodiment are cylindricalcomponents 14A, 14B at an approximately 120 degree angle to each other.The cylindrical components 14A, 14B can also be referred to herein asshoulders, including a right shoulder 14A and a left shoulder 14B. Inthe embodiment depicted in FIG. 2A, the two components 14A, 14B arecoupled directly to each other. Alternatively, the two components arenot coupled to each other or, in another option, can be individuallycoupled to an access port used in the surgery. In a further alternative,the body 12 (and any body of any device embodiment disclosed herein) canbe a single component and further can be any of the device bodyembodiments disclosed in the various patent applications incorporated byreference above and elsewhere herein.

The body 12 is connected to two arms 16, 18 in one example of thedevice. In the implementation shown, the right shoulder 14A is coupledto right arm 16 and left shoulder 14B is coupled to left arm 18. Inaddition, the body 12 is also coupled to a support component 20, as bestshown in FIG. 8. In accordance with one implementation as shown in FIGS.6A and 6B and described in additional detail below, the support rod 20as configured is a support rod 20 that is made of two coupleable supportrod components 20A, 20B, each of which is independently attached to oneof the body components 14A, 14B. More specifically, the supportcomponent 20 has a first support rod component 20A that is coupled tothe first shoulder 14A and a second support rod component 20B that iscoupled to the second shoulder component 14B. Alternatively, the supportcomponent 20 can be a single, integral component coupled to the body 12.In certain implementations, the support component 20 can be a rod, tube,or other applicable shape.

Returning to FIG. 2A, each of the arms 16, 18 have a first joint 16A,18A (each of which can also be referred to as a “shoulder joint”) thatis coupled to the body components 14A, 14B. Each first joint 16A, 18A iscoupled to a first link 16B, 18B (also referred to as a “first segment,”an “upper segment,” or an “upper arm”), each of which is rotatablycoupled to a second link 16C, 18C (also referred to as a “secondsegment,” a “lower segment,” or a “forearm”) via a second joint 16D, 18D(each of which can also be referred to as an “elbow joint”). Inaddition, each arm 16, 18 also has an operational component (alsoreferred to as an “end effector”) 16E, 18E coupled to the forearm 16C,18C. It is understood that the operational components 16E, 18E (and anyof the operational components on any of the embodiments disclosedherein) can be any known operational components, including any of theoperational components disclosed in the various patent applicationsincorporated by reference above and elsewhere herein. By way of example,the components 16E, 18E can be cautery devices, suturing devices,grasping devices, imaging devices, operational arm devices, sensordevices, lighting devices or any other known types of devices orcomponents for use in surgical procedures.

As mentioned above and as shown in FIG. 2B, the first links 16B, 18B arecoupled to the body 12 via shoulder joints 16A, 18A. In one embodiment,each shoulder joint 16A, 16B is a joint having two axes of rotation. Forexample, as will be described in further detail below, the left shoulderjoint 18A can be configured to result in rotation of the upper arm 18Bas shown by arrow A around axis AA (that substantially corresponds tothe longitudinal axis of the body 12) and also as shown by arrow Baround axis BB, which is substantially perpendicular to axis AA. Becauseright shoulder joint 16A and right upper arm 16B are substantially thesame as the left shoulder joint 18A and the left upper arm 18B, theabove description also applies to those substantially similar (oridentical) components. Alternatively, any known joint can be used tocouple the upper arms 16B, 18B to the body 12.

Continuing with FIG. 2B, the upper arms 16B, 18B, according to oneimplementation, are coupled to the forearms 16C, 18C, respectively, atthe elbow joints 16D, 16D such that each of the forearms 16C, 18C canrotate. For example, the forearms 16C, 18C can rotate as shown by arrowC around axis CC. Further, the end effectors 16E, 18E can also rotaterelative to the forearms 16C, 18C, respectively, as shown by arrow Daround axis DD. In addition, each of the operational components 16E, 18Ecan also be actuated to move between at least two configurations, suchas an open configuration and a closed configuration. Alternatively, theoperational components 16E, 18E can be coupled to the forearms 16C, 18C,respectively, such that the operational components 16E, 18E can be movedor actuated in any known fashion.

According to one embodiment, the operational components 16E, 18E, suchas graspers or scissors, are also removable from the forearms 16C, 18C,such that the operational components 16E, 18E are interchangeable withother operational components configured to perform other/different typesof procedures. Returning to FIG. 2A, one operational component 16E is agrasper 16E commonly known as a babcock grasper and the other 18E is avessel sealing grasper 18E. Alternatively, either or both of thecomponents 16E, 18E can be cautery devices, suturing devices, graspingdevices, or any other known types of devices or components for use insurgical procedures, or can be easily replaced with such components.

It is understood that the device 10 in this embodiment contains themotors (also referred to as “actuators,” and intended to include anyknown source of motive force) that provide the motive force required tomove the arms 16, 18 and the operational components 16E, 18E. In otherwords, the motors are contained within the device 10 itself (either inthe body, the upper arms, the forearms or any and all of these), ratherthan being located outside the patient's body. Various motorsincorporated into various device embodiments will be described infurther detail below.

In use, as in the example shown in FIG. 3, the device 10 is positionedinside a patient's body cavity 30. For example, in FIG. 3, the bodycavity 30 is the peritoneal cavity 30.

According to one implementation, the device 10 can be sealed inside theinsufflated abdominal cavity 30 using a port 32 designed for singleincision laparoscopic surgery. Alternatively, the device 10 can beinserted via a natural orifice, or be used in conjunction with otherestablished methods for surgery. The device 10 is supported inside theabdominal cavity using the support rod 20 discussed above. Thelaparoscopic port 32 can also be used for insertion of an insufflationtube 34, a laparoscope 36 or other visualization device that may or maynot be coupled to the device assembly. As an example, a 5 mm laparoscope36 is shown in FIG. 3.

Alternatively, as shown in FIG. 4, a cannula or trocar 40 can be used inconjunction with the port device 32 to create a seal between the cavityand the external environment. Alternatively, any other known surgicalinstrument designed for such purposes can be used in conjunction withthe port device 32 to create a seal between the cavity and the externalenvironment, as is discussed below with regard to FIG. 9.

According to one alternative embodiment as shown in FIG. 5, asuction/irrigation tube 50 can be coupled with the device 10 and usedfor surgical suction and/or irrigation. In this embodiment, the tube 50is coupled to the forearm 16C of the right arm 16. More specifically,the forearm 16C has a channel 52 defined on an exterior surface of theforearm 16C that is configured to receive and removably hold the tube50. In use, the tube 50 can extend from the device 10 and through anorifice to an external device or system for use for surgical suctionand/or irrigation. Alternatively, the tube 50 can be coupled to the leftarm 18 or some other portion of the device 10. In a further alternative,the tube 50 can be disposed internally within the arm 16 or othercomponent of the device 10.

In use, the device 10 can first be separated into the two smallercomponents as described above and then each of the two components areinserted in consecutive fashion through the orifice into the bodycavity. In accordance with one implementation, due to the limitationsassociated with the amount of space in the cavity, each of thecomponents can form a sequence of various configurations that make itpossible to insert each such component into the cavity. That is, eachcomponent can be “stepped through” a sequence of configurations thatallow the component to be inserted through the orifice and into thecavity.

For example, according to one implementation shown in FIGS. 6A and 6B,the device 10 can be inserted through a single orifice by physicallyseparating the device 10 into separate, smaller components and insertingthose components through the single orifice. In one example, the devicecan be separated into two “halves” or smaller components, in which onehalf 10A as shown in FIGS. 6A and 6B consists of the right shoulder 14Acoupled to the right arm 16. Similarly, while not depicted in FIGS. 6Aand 6B, the other half consists of the left shoulder 14B coupled to theleft arm 18. It is understood that the left arm 18 is substantiallysimilar to or the same as the right arm 16 such that the description ofthe right arm herein and the depiction in FIGS. 6A and 6B apply equallyto the left arm 18 as well. In this implementation, the right shoulder14A is coupled to the right support rod component 20A (and the leftshoulder 14B is similarly coupled to the left support rod component20B). Alternatively, this device 10 or any device contemplated hereincan be separated into any two or more separable components.

FIGS. 6A and 6B show how the right support component 20A can berotationally coupled to the shoulder 14A, thereby resulting in movementof the shoulder 14A in relation to the right support component 20Abetween at least two configurations, making insertion of the overalldevice into a patient's cavity easier. More specifically, the rightdevice half 10A is shown in FIG. 6A in its operational configuration inrelation to the right support component 20A such that the right devicehalf 10A can be coupled to the left device half 10B (not shown) andthereby used to perform a procedure in the patient's cavity. Note thearrow 21 in FIG. 6A illustrating how the right support component 20A canrotate in relation to the right shoulder 14A. FIG. 6B, on the otherhand, depicts the right device half 10A in its insertion configurationin which the right shoulder 14A has been rotated in relation to theright support component 20A, thereby making the device half 10A easierto insert through an orifice and into a patient's cavity. In use, thedevice half 10A is “stepped through” the two configurations to easeinsertion. First, the device half 10A is placed in the insertionconfiguration of FIG. 6B and inserted through the orifice. Subsequently,once the right arm 16 is positioned inside the patient's cavity, theright shoulder 14A can be rotated in relation to the right supportcomponent 20A to move the device half 10A into the operationalconfiguration of FIG. 6A such that the device half 10A can be coupled tothe other half 10B and subsequently be used to perform a procedure.

When the device half 10A is properly positioned in the patient's cavity,the first support rod component 20A, which is coupled to the rightshoulder 14A, is disposed through an orifice or any other kind ofopening in the body cavity wall (shown as a dashed line in FIG. 7) suchthat the distal portion of the support rod component 20A coupled to thefirst shoulder 14A is disposed within the body cavity 30 while theproximal portion is disposed outside of the patient's body and can beattached to an external component (not shown) so as to provide stabilityor fixed positioning for the device.

As discussed above, in this example, the two coupleable support rodcomponents (such as 20A as shown in FIGS. 6A, 6B, and 7) can bepositioned next to one another or coupled to each other form acylindrical shape or a complete rod 20. In the example in FIG. 8, anovertube 60 can then be placed over the rod 20. As best shown in FIG. 9,this overtube 60 can be held in place with a threaded thumbscrew 61 andthe entire rod 20 and overtube 60 assembly can then be inserted into thelaparoscopic port 32. As best shown in FIG. 10, once assembled, othertools can then be inserted into the port such as a cannula for asuction/irrigation tube 34 as described above, a laparoscope 36 asdescribed above, and/or other surgical instruments, and positionedthrough the port 32 via port openings 32A, 32B, 32C (as best shown inFIG. 9). These figures illustrate one example of how this assembly canbe configured to accept a cannula for suction and irrigation or othercomponent 33.

Alternatively, the device body 10 can be a single component that iscoupled to both support rod components 20A, 20B, which are coupled toeach other to form a full support rod 20.

Once assembled, an external device (not shown) can be used to stabilizethe support component assembly. According to this implementation, thedevice 10 is maintained in a desired position or location within thebody cavity of the patient using an external component that has a clampthat is removably attached to the support component 20. Alternatively,the external component can have any known attachment component that iscapable of removably coupling to or attaching to support component.

As an example, the external component can be an iron intern(commercially available from Automated Medical Products Corp.) thatincludes several sections connected by joints that can be loosened andlocked using knobs to allow the iron intern to be positioned in variousorientations. The iron intern can be attached to rails on any standardsurgical table or any other appropriate surface to provide support fordevice.

In use, according to one embodiment, the device 10 is positioned withinthe body cavity of the patient and the support component assembly 20 ispositioned through a port 32 positioned in the hole or opening in thebody cavity wall, as shown, for example, in FIG. 3. In one embodiment,the port 32 is a gel port through which the support component 20 can bedisposed while still maintaining a fluidic seal that allows for the bodycavity 30 of the patient to be inflated. Alternatively, any known port32 that provides access for the support component 20 while maintaining afluidic seal can be used. Also, any cables, electrical or otherwise, canbe coupled to the device 10 via this port 32. In one embodiment,electrical cables pass through the support rod 20 or other supportcomponents.

FIG. 11 depicts one example of how a laparoscope 36 in one embodimentcan be used in conjunction with the device 10 to provide visualizationof the working space of the robotic assembly. More specifically, FIG. 11shows how a “zero degree” laparoscope 36 can provide a large field ofview (shown as cone 70) enabling the user to view the surgicalenvironment. Other visualization means are also possible and these caneither be separate from or attached to the robotic device 10. Thevisualization means can also enter though other orifices in the bodycavity to be used independently or in conjunction with the roboticdevice 10.

FIGS. 12A-17 depict exemplary embodiments of how such a medical devicecan be mechanically and electrically constructed.

FIGS. 12A-12D show one design of a forearm 80 having a vessel sealingoperational component or end effector 82. The vessel sealing device 82may or may not include a cutting component and different types ofcautery techniques. In this example, as best shown in FIGS. 12B and 12D,a first actuator 84 is coupled to the end effector 82 by spur gears 84A,a second actuator 86 is coupled to the end effector 82 by spur gears86A, and a third actuator 88 is coupled to the end effector by spurgears 88A. These first, second and third actuators 84, 86, 88 providerotation of the end effector 82 along the axis of the forearm 80 (axisDD as described in FIG. 2), opening and closing motion for the endeffector 82, and can cause a cutting device (not shown) to translatethrough the end effector 82.

FIGS. 12A-17 also show various printed circuit boards 114A-114J used topower and control the actuators. Each actuator has one or more sensorsto measure the position of the components for control. These caninclude, but are not limited to, optical encoders, mechanical encoders,or potentiometers. Each sensor can either measure relative or absoluteposition.

FIGS. 13A-13D depict another embodiment of a forearm 90 for a roboticmedical device. This embodiment shows an interchangeable operationalcomponent 92, which, in this specific example, is a grasper 92 commonlycalled a Babcock grasper. These interchangeable operational componentscan be similar to the interchangeable tools called Microline made by thePentax Company. In this embodiment, as best shown in FIGS. 13B and 13C,the interchangeable tools are held in place using a known taperedcollect device 94 (commonly used in machine tools) to hold theoperational component in place. Here, the operational component isinserted into a tapered collect 94 that is then tightened in place usinga threaded nut and a tapered slot 96. In this example, as best shown inFIG. 13D, there are two actuators 97, 98 that actuate open and closingof the operating component and rotation of the operating component(about axis DD as described above) by way of corresponding spur gears97A, 98A with respect to the forearm 90. In this design, as an example,the operational component can be electrified for either mono-polar orbipolar cautery.

FIG. 14 shows how a fuse clip 100, or similar sliding contact device,can be used to provide an electrical connection to one or more portionsof the operational component (not shown) to provide electricity forcautery. For example, as shown in the figure, the fuse clip 100 iscoupled to a shaft 102 which may spin or rotate, the fuse clip 100acting to maintain electrical connectivity to the shaft 102 for supplyto the operational component (not shown) for cautery without the use ofwires that may tangle and bunch. FIG. 14 also shows a printed circuitboard (PCB) 114 that contains electronics to power and control theactuators as described previously. More specifically, in this particularfigure, the PCB 114 is coupled to the actuator (not shown) such that itmay control the electrification of the shaft 102 and ultimately theoperational component (not shown).

FIGS. 15A-15D show one possible upper arm segment 16B embodiment. Thissegment 16B has two actuators 104, 106 that provide rotation of theforearm segment relative to the upper arm 16B and the upper arm 16Brelative to the body 14, as described, for example, as axis CC and axisBB in FIG. 3, respectively. In this design, the two actuators 104, 106are operably coupled to bevel gears 104A, 106A by way of drive gears104B, 106B to change the axis of rotation of the motors 104, 106 byninety degrees and make the two axes of rotation (CC & BB) perpendicularto the axes of the segment 16B. Also shown are the sensors andelectronics used to control the segment 16B as described above.

FIGS. 16A-16D show one possible device body segment 14A embodiment.Here, an actuator 110 is coupled to the output shaft 112 by bevel gears113A, 113B such that the axis of actuator 110 rotation is approximately30 degrees from the axis of rotation of the output shaft 112. Also shownare the sensors and electronics used to control the actuator 110 in thebody segment 14A in a fashion similar to that described above.

FIGS. 17A and 17B depict one possible implementation of a device 10having printed circuit boards 114A-J and connective electrical cables116A-J that are contained and routed inside the device 10 to provideelectrical power and control. More specifically, FIG. 17A depicts thecables 116A-116J and FIG. 17B depicts the PCBs 114A-114J. In thisexample, “service loops” are provided at each joint to allow forrelative motion between the links while not placing the cables inexcessive bending or tension (not shown). Alternatively, the circuitboards and cabling can be positioned outside the robot.

FIG. 18 shows a general schematic for one possible design of theelectrical sub-system of a robotic device in accordance with oneembodiment. The schematic shows an example of the electronics for avessel sealing arm, such as, for example, the right arm in the robot 10depicted in FIGS. 2A and 2B. In this example as shown schematically inFIG. 18, the connection cable 122 enters through the support rod 120.This cable 122 can contain conductors for electrical power andelectrical signals and other wires of various forms as required foroperation of the device 10. This cable 122 interfaces with the shoulderpitch PCB 124. This shoulder pitch PCB 124 supports both an opticalencoder 126 and a magnetic encoder 128 for redundant measurement ofrotation of the first shoulder joint 18A (around axis AA) as shown inFIGS. 2A and 2B. This PCB 124 provides power to the shoulder pitch motor128 (for rotation around axis AA). It can also be seen that the cable122 (via connectors J1 and J2) passes via a service loop 130 into themain joint 18B (described as the upper arm above). Here a “service loop”130A, 130B, 130C, 130D, 130E is provided at each joint to allow forrelative motion between the links while not placing the cables inexcessive bending or tension.

The shoulder pitch PCB is also connected to the upper arm via a serviceloop 130B and connectors (J3 & J4). In the upper arm 18B there is anupper arm shoulder PCB 132 (for axis BB in FIG. 2B) and an upper armelbow PCB 134 (for axis CC). This link also has internal connectors J5 &J6. All connectors generally aid and allow for assembly and repair. BothPCBs 132, 134 in this link power an actuator 136, 138 for each joint(axis BB & CC) as well as both optical 140, 142 and magnetic 144, 146encoders to measure joint position. The sensors in this arm andthroughout the robot can be used redundantly and or individually or incombination. They can be either relative or absolute or in anycombination. There are also connections from the upper arm to the lowerarm via connectors listed as J7, J8, J18 & J19 and via service loops.

Here and throughout the robot service loops may or may not be required.The forearm contains three PCBs 150, 152, 154 to drive/control thegripper cutting device 154A, the gripper jaws 152A and the gripper roll150A (axis DD). As before various sensors 156 and motors 150A, 152A,154A are powered and used with the PCBs and various service loops 130C,130D, 130E are used. As shown previously, the gripper can be electrifiedfor cautery with one or more clips or connectors (or with a directconnection) that may or may not allow relative motion of the gripperjaws (axis DD). This example design shows a PCB for each joint.Alternatively a PCB could be used for each link, or each arm, or anycombination of the above. The description above and shown in FIG. 21 isjust one example of the electrical design that is possible.

FIG. 19 shows a general schematic for yet another possible design of theelectrical sub system of the robotic device. The schematic in FIG. 19shows an example of the electronics for an arm with interchangeabletools, also referred to as the utility arm or left arm 18 in the designof FIGS. 2A-2B. In this example the electronics, PCBs, connectors, andservice loops, etc are similar to the schematic described in FIG. 18 butthis arm does not have a cutting device and hence does not have onactuator and supporting mechanical and electrical components. Again, asshown previously, the gripper can be electrified for cautery with one ormore clips or connectors (or with a direct connection) that may or maynot allow relative motion of the gripper jaws (axis DD).

Again, in this version both operating components (vessel sealing andinterchangeable Babcock grasper) can be electrified for cautery. Ingeneral any and combination of the operating components can beelectrified with either no cautery, mono-polar cautery, bi-polarcautery, or other surgical treatment technique.

The robotic surgical device described here can be either single use andbe designed to be disposed of after its use, or can be made so it can bere-used and sterilized between uses. In one embodiment, to ease cleaningof the device between uses, a protective sleeve is disclosed here thatcovers the majority of the outer surfaces of the robotic device.

According to one embodiment, shown in FIGS. 20A-20B, a dip mold pattern200 (best shown in FIG. 20B) is created with a shape and size that issimilar to the robotic arm 202 (best shown in FIG. 20A) (also called autility arm or ligisure arm or other arm, for example 16, 18 in FIGS.2A-2B) for which a protective sleeve is needed. The dip mold pattern 200is designed in such a way as to be thicker and larger than the arm 202in specific areas, such as, for example, around the joints 201A-D. Thislarger size will result in a protective sleeve 200 that is larger inthese areas so it will provide slack for the robotic arm 202 toarticulate.

Also, according to one embodiment, FIG. 20A shows how features 204A,204B (or “grooves”) are designed into the robotic device 202. In thisembodiment, one groove 204A is at the proximal end of the robotic arm202 and a second 204B is at the distal end of the arm 202. These grooves204A, 204B are designed so the protective sleeve 200 will form a tightseal and mechanical connection with the robotic arm 202 to make the armfluidically sealed.

In another embodiment, a mold, grooves, and sleeve could be created ateach the proximal and distal ends of the joints so smaller protectivesleeves would be created that would only cover the joint areas. Othercombinations are also possible. For example one sleeve could cover twoproximal joints and a second sleeve could cover a distal joint.

In use according to one embodiment as shown in FIGS. 21A and 21B, thedip mold pattern 200 can be placed into a vat 210 of dip mold material212. In one embodiment, this mold material 212 could be a latex orsimilar material. The pattern can then be removed from the vat 210 andthe mold material 212 is then cured in a heated oven 213. The processcan be repeated to create multiple layers and thereby a thicker sleeve.

When the mold material is cured, according to one embodiment and shownin FIGS. 22A and 22B, the resulting protective sleeve 214 can be trimmedat each end and then the ends can be rolled 216A, 216B. Rolling the endscreates “beads” at both the proximal 216A and distal 216B ends of theprotective sleeve. These “beads” 216A, 216B are designed to fit in thegrooves 204A, 204B or other external features or contours (shown as anexample in FIG. 20) on the robotic device. The sleeve 214 is thenremoved from the dip mold 200 and placed onto the robotic arm 202. Itcan be seen how the protective sleeve 214 now covers and protects mostor all of the robotic arm 202 (including the moving joints) from fluidingress during surgery.

While multiple embodiments are disclosed, still other embodiments of thepresent invention will become apparent to those skilled in the art fromthe following detailed description, which shows and describesillustrative embodiments of the invention. As will be realized, theinvention is capable of modifications in various obvious aspects, allwithout departing from the spirit and scope of the present invention.Accordingly, the drawings and detailed description are to be regarded asillustrative in nature and not restrictive.

Although the present invention has been described with reference topreferred embodiments, persons skilled in the art will recognize thatchanges may be made in form and detail without departing from the spiritand scope of the invention.

I claim:
 1. A modular surgical robotic system, comprising: a. a modularrobotic device sized to be positioned completely within a patientfurther comprising: i. a body component further comprising a firstshoulder component and a second shoulder component; ii. a first movablesegmented robotic arm comprising a housing with at least one motordisposed within the housing and operationally connected to the bodycomponent by way of the first shoulder component; iii. a second movablesegmented robotic arm comprising a housing with at least one motordisposed within the housing and operationally connected to the bodycomponent by way of the second shoulder component; iv. a firstoperational component operationally connected to the first robotic arm;and v. a second operational component operationally connected to thesecond robotic arm; b. a port configured for traversing the body of apatient; c. a support rod for crossing the port from the interior toexterior of the patient and connecting to the first and second bodycomponents; and d. an operations system for control of the modularrobotic device from outside the patient by way of the port and supportrod, the operations system in electrical communication with the modularrobotic device.
 2. The modular surgical robotic system of claim 1,wherein the modular robotic device may be assembled within the bodycavity of the patient.
 3. The modular surgical robotic system of claim2, wherein the support rod is further comprised of a first support rodsegment and a second support rod segment.
 4. The modular surgicalrobotic system of claim 3, wherein the first support rod component andsecond support rod component are rotationally coupled to the firstshoulder component and second shoulder component, respectively.
 5. Themodular surgical robotic system of claim 4, wherein the support rod issubstantially enclosed in an overtube.
 6. The modular surgical roboticsystem of claim 1, wherein the body component is cylindrical.
 7. Themodular surgical robotic system of claim 1, wherein the first shouldercomponent and second shoulder component are set at an obtuse angle fromone another.
 8. The modular surgical robotic system of claim 1, whereinthe first operational component is chosen from a group consisting of agrasping component, a cauterizing component, a suturing component, animaging component, an operational arm component, a sensor component, anda lighting component.
 9. The modular surgical robotic system of claim 1,wherein the second operational component is chosen from a groupconsisting of a grasping component, a cauterizing component, a suturingcomponent, an imaging component, an operational arm component, a sensorcomponent, and a lighting component.
 10. The modular surgical roboticsystem of claim 1, further comprising one or more motors for operation,rotation or movement of at least one of the first shoulder, the secondshoulder, the first segmented arm, the second segmented arm, the firstoperational component, and the second operational component.
 11. Themodular surgical robotic system of claim 1, wherein the port creates aninsufflation seal in the body.
 12. A modular surgical robotic system,comprising: a. a modular robotic device sized to be positionedcompletely within a patient further comprising: i. a first shouldercomponent; ii. a second shoulder component; iii. a body component,formed by the connection of the first shoulder component to the secondshoulder component; iv. a first movable segmented robotic arm comprisingat least one motor and operationally connected to the body component byway of the first shoulder component; v. a second movable segmentedrobotic arm comprising at least one motor and operationally connected tothe body component by way of the second shoulder component; vi. a firstoperational component operationally connected to the first robotic arm;and vii. a second operational component operationally connected to thesecond robotic arm; b. a port configured for traversing the body of apatient; and c. an operations system for control of the modular roboticdevice from outside the patient by way of the port and support rod, theoperations system in electrical communication with the modular roboticdevice.
 13. The modular surgical robotic system of claim 11, wherein themodular robotic device may be assembled within the body cavity of thepatient.
 14. The modular surgical robotic system of claim 11, whereinthe body component is cylindrical.
 15. The modular surgical roboticsystem of claim 11, wherein the first shoulder component and secondshoulder component are set at an obtuse angle from one another.
 16. Themodular surgical robotic system of claim 11, wherein the firstoperational component is chosen from a group consisting of a graspingcomponent, a cauterizing component, a suturing component, an imagingcomponent, an operational arm component, a sensor component, and alighting component.
 17. The modular surgical robotic system of claim 11,wherein the second operational component is chosen from a groupconsisting of a grasping component, a cauterizing component, a suturingcomponent, an imaging component, an operational arm component, a sensorcomponent, and a lighting component.
 18. The modular surgical roboticsystem of claim 11, further comprising one or more motors for operation,rotation or movement of at least one of the first shoulder, the secondshoulder, the first segmented arm, the second segmented arm, the firstoperational component, and the second operational component.
 19. Themodular surgical robotic system of claim 11, wherein the port isconstructed and arranged to create an insufflation seal in the body ofthe patient.
 20. A method of performing minimally invasive surgery,comprising: a. providing a modular robotic device sized to be positionedcompletely within a patient further comprising: i. a body componentfurther comprising a first shoulder component and a second shouldercomponent; ii. a first movable segmented robotic arm operationallyconnected to the body component by way of the first shoulder component;iii. a second movable segmented robotic arm operationally connected tothe body component by way of the second shoulder component; iv. a firstoperational component operationally connected to the first robotic arm;and v. a second operational component operationally connected to thesecond robotic arm; b. providing a fluidly sealed port disposed acrossthe body cavity wall of a patient and transversed by the support beamand support rods, c. providing a support rod for crossing the port fromthe interior to exterior of the patient and connecting to the first andsecond body components, said support rod being further comprised of atleast one rod component; d. inserting the modular surgical roboticsystem components into the body of the patient by way of the port usingthe support rod; and e. assembling the modular surgical robotic systeminside the body of the patient for use.